Winding machine



13 1955 D. 1. WILSON WINDING MACHINE l2 Sheet-Sheet 1 Filed Dec. 6, 1951 N VENTOR. Delbert lit/115011 Dec. 13, 1955 D. 1. WILSON WINDING MACHINE l2 Sheets-Sheet 2 Filed Dec. 6, 1951 n 0 :6 1 WW m M r e .b e D Dec. 13, 1955 Filed Dec. 6, 1951 D. 1. WILSON WINDING MACHINE 12 Sheets-Sheet 3 IN VEN TOR.

Delbert 1. Wilson Z M/H L Gtiy.

WINDING MACHINE Filed Dec. 6, 1951 12 Sheets-Sheet 4 INVENTOR. w Delbert I.- Wilson BY 42M 1 2,

Dec. 13, 1955 D. l. WILSON WINDING MACHINE l2 Sheets-Sheet 5 Filed Dec. 6, 1951 INVENTOR. Delbert I. Wilson Dec. 13, 1955 D. 1. WILSON WINDING MACHINE Dec. 13, 1955 D. 1. WILSON WINDING MACHINE l2 Sheets-Sheet 7 Filed Dec. 6, 1951 INVENTOR. Delbert I. Wilson Dec. 13, 1955 Filed Dec. 6, 1951 D. I. WILSON WINDING MACHINE 12 Sheets-Sheet 8 INVENTOR. Delbert I. Wilson Z/Mf Dec. 13, 1955 D. I. WILSON 2,726,320

WINDING MACHINE Filed Dec. 6, 1951 12 Sheets-Sheet 9 Z4 l 26 I INVENTOR. Delbert 1. Wilson Dec. 13, 1955 w so 2,726,820

WINDING MACHINE Filed Dec. 6, 1951 12 Sheets-Sheet 1O INVENTOR. Delbert I. Wilson Dec. 13, 1955 o. WILSON WINDING MACHINE l2 Sheets-Sheet 11 Filed Dec. 6, 1951 INVENTOR. Delbert 1. Wilson ZM/f Dec. 13, 1955 D. |.-WILSON WINDING MACHINE l2 Sheets-Sheet 12 Filed Dec. 6, 1951 w n R a? Ill 00 M mL t r 00 m) m 2 e D M United States Patent O WHVDING MACHINE Delbert 1. Wilson, Tipp City, Ohio, assignor to McGraw Electric Company, Elgin, 111., a corporation of Delaware Application December 6, 1951, Serial No. 260,260

Claims. (Cl. 242-9) copen-ding application Ser. No. 186,476, filed September 20, 1950, by Waldo H. Zander, Fred D. Zander and Delbert I. Wilson.

Objects of the invention include the provision of a Winding machine for flat coils that is simpler, more rugged,

more dependable, and faster in operation, that has its work-supporting parts more open so as to facilitate loading and unloading.

A further object is to provide such a machine in which the moving parts are smaller, lighter, more compact and better supported.

To this end, we provide a machine having a rotatably oscillating movement for laying successive spans of Wire or the like across one side of a coil form, and a coil-form holder that is shifted step by step in timed relation to the oscillations. Further, the coil-form holder is carried by a rotatable support for oscillation therewith and shifting movement thereon for executing the winding operation.

These and other objects and advantages of the present invention will appear from the following description of one specific embodiment thereof which illustrates the manner in which the invention may be put into practice.

In the drawings:

Fi s. 1, 2 and 3 show a part of the winding machine of the present invention in three successive stages of winding a single-faced heating element on a flat form;

Fig. 4 shows a completed heating element;

Fig. 5 is a View of the form holder in its retracted position as seen from the front, that is, from the side on which the form is carried;

Figs. 6, 7 and 8 are sectional views of the form holder taken as indicated in Fig. 5;

Figs. 9 and 10 are pictorial views of the front and back of the rotatable form-holder in extended position (both as seen from the front of the machine);

Figs. 11 through 17 are detail views showing steps in the operation of laying the wire on the form holder and securing it in the notched edges; Fig. 11 shows the position of the ribbon after the form holder has been manually loaded and the ribbon manually fitted into the first notch; Figs. 12 and 13 show laying of the first span; Figs. 14 through 16 show the indexing movement of the form under wire guide and the fonnation of the loop in the ribbon; Fig. 17 shows the loop drawn taut through the second notch for securing the ribbon;

Fig. 18 is a pictorial skeleton view of the machine, partly diagrammatic for showing its operating parts;

Fig. 19 is a diagram of the electric control circuits;

Figs. 20 and 21 are front and right end elevations of the machine;

Fig. 22 is a longitudinal (front) elevational section 2,726,820 Patented Dec. 13, 1955 ice 2 through the machine taken substantially as indicated in Fig. 21;

Figs. 23 through 26 are transverse, vertical sections taken as indicated in Fig. 22;

Fig. 27 is a horizontal section taken as indicated in Fig. 22; and

Figs. 28 and 29 are detailed sections taken as indicated in Fig. 26.

Fig. 4 shows a complete heating element of the type that may be wound on the machine of the present invention. This particular element is designed for use in an electric toaster. It includes a flat mica sheet or form 10, electric resistance wire 12 in the form of ribbon secured in notches 14 along two of its opposite edges, wire staples 16 for supporting the centers of the spans of ribbon, metal grommets 18, two of which secure-the ends of the wire and serve as electric terminals, insulating mounting pieces 20 held by the grommets 18, and metal clip 22 having mounting tongues 24. The flat mica form 10 also includes notches 26 that are used for locating the form in the winding machine. The right-hand end of the finished heating element as seen in Fig. 4 is the bottom of the element as it is used in a toaster. Since heat rises the spans of wire are closer together at the bottom than at the top.

In general, the winding operation is accomplished by manually loading the form 10 in the machine with the ribbon laid in the first notch 14, as shown in Fig. 1. The machine then rotatably oscillates the form 10 about its horizontal center l ne, as seen in Fig. 1, for laying spans of the ribbon successively across the face of the form and for engaging it in the notches 14. The form 19 is moved in steps to the right relative to both the wire feed roller 28 and wire guides 30 and 32, and in time with the oscillations so that the winding progresses along the form as shown in Fig. 2. At the end of the winding operation the form returns automatically to the leftmost or retracted position as shown in Fig. 3, and the machine stops in this position. The wire is cut and the form is removed manually.

As shown in Figs. 5 through 10 the form holder 34 is mounted for longitudinal movement on a rotatable carrier 36 which is supported by and driven through a trunnion like part 38. The longitudinal motion of the form holder is controlled by the reciprocating rod 40 which also partially supports the form-holder 34. The form holder is further guided and supported by rollers 42 (Figs. 5 and 7) journaled in brackets 43 on the carrier 36, near the wire guides 3i) and 32 (Fig. 5). These rollers engage concave tracks 44 on opposite sides of the formholder 34, as best seen in Fig. 7. The form-holder 34 is a platform or paddle-like member carrying two opposed undercut bars 46 and 48 for holding the form in place. Bar 43 is mounted on a movable block 50, which slides between bearing plates 51 in an opening in the plate 34, is held in place by the bar 48 at the front and another cleat-like piece 52 at the back, and is controlled by rod 54 which in turn is moved by a pivoted handle 56. A spring-urged ball detent 58 (Figs. 5 and 8) in the block 50 serves to hold it in its form-retaining position during the winding operation. The form-holding bars 46 and 48 include projections 6i? and 62 that fit notches 26 of the form for locating it accurately on the form holder. As may be seen best in Figs. 7, 9 and 10, the wire guides 34 and 32 are supported on the brackets 43. The mechanism for feeding the ribbon 12 through rollers 28 appears in Figs. 26 and 21 but is not described in detail here because it is substantially like that shown and described in prior application Ser. No. 186,476.

Figs. 11 through 17 show details of the process of laying the spans and securing the ribbon in the supporting notches of the flat form. Fig. 11 is a sectional view looking toward the left in Fig. 1 showing the position of the wire and form just after it has been manually loaded. As may be seen in both Figs. 1 and .11, the block 70 and the hinged cap 72 of the wire guide 30 embrace the edge'of' the flat form 10. Further, the space between the cap 72 and the block 74 constitutes a small wireguiding gap which is aligned with the rightmost notch 14 on the form. The form 10 oscillates substantially about its longitudinal center line 75. Initial motion of the form holder is a counter-clockwise rotation from the position of Fig 11 to that of Fig. 12 for laying the form 10 against the ribbon 12, pulling the ribbon into the first notch, and drawing an extra length of ribbon as shown in Figs. 12 and 13. Although wire 12 comes from the rollers 28 of the wire-feeding mechanism under tension, that mechanism includes a grip or check for preventing retraction of the wire. wise rotation of the form-holder from the position of Fig; 12 leaves the Wire slack. However, as clockwise rotation begins,'the form-holder 34 (see Figs. 1 and moves one step (to the right as seen in Figs. 1 and 5, to the left as seen in Fig. 13) for bringing the netx notch 14 of the form into alignment with the guide space between parts 72 and 74 of the wire-guide 30. This motion of the form 10 carries the first notch, the one containing the wire, behind the 'cap 72 which then prevents the ribbon 12 from slipping out of the notch. As shown in Fig. 16 the reach of the wire then extends from the back of the notch under a triangular horn-shaped piece 76 that extends from the block 70 and lies behind cap 72. As the form-holder continutes its rotation clockwise from the position of Fig. 12, a loop forms in the slack wire as shown in Fig. 14. As the clockwise rotation continues the loop first pulls tight over the born 76 approximately in the position shown in Fig. 15 and then slips down into the second notch, as shown in Fig. 17, to complete one fastening of the wire 12. Successive spans and fastenings are formed similarly. Thus the clockwise rotation of the form-holder continues from the position of Fig. 16 until the ribbon 12 passes into the wire guide 32. Then the form indexes its second step (to the right as seen in Figs. 1 and 2), the rotation reverses, and the second span is secured. The full arc of oscillation of the form holders is about 260.

The preceding operations are controlled automatically by the mechanism and electric circuit as shown in Figs. 18 and 19. The purpose of Figs. 18 and 19 is to depict the organization and operation of the equipment and certain proportions have been altered and certain parts shown diagrammatically therein for facilitating explanation. The actual construction of the mechanical parts are shown in Figs. 1 through 17, and 20 through 29.

In Fig. 18 a power unit 90 includes an electric motor,

an electric brake and a geared speed reducer. This unit drives a shaft 92 to which are keyed gears 94 and 96. A drum cam 93, while surrounding the shaft 92, is not fixed to it but is driven through gears 94, 1130, 102, 104 and 106 (see also Figs. 22 and 23). The trunnion support 38 of the oscillating carrier 36 (also shown in Figs. 1 and 5) is driven from gear 96 through gear 108, eccentric 119, gear sector 112, and hollow pinion 114 (see also Figs; 22, 26, 28 and 29). The rod 40 which controls the longitudinal motion of the paddle-like form-holder 34 (also shown in Figs. 5 and 6) extends through the trunnion 38 and pinion 114 and is fastened by a thrust bearing to a reciprocating carriage 116 (see also Figs. and 27) which is connected by reciprocating rod 118 to a double-acting air cylinder 120.

Although driven to the right by the air cylinder 12%), the carriage 116 and the form-holder 34 have their motion controlled by the drum cam 98. This cam has 18 steps spaced 20 apart at its circumference for moving the form-holder 34 longitudinally at the completion of each of the 18 spans of wire that are laid on automati- Consequently clock- 4 cally. Note that although the completed heating element of Fig. 4 has 19.spans of wire, only 18 of these are completed by the machine, as shown in Fig. 3. The gear ratios are such that the form-holder 34 is oscillated back and forth nine times (for laying l8 spans) during one rotation of the drum cam 98. The steps of the cam are spaced longitudinally to correspond to the graduated spacings of the notches in the form 10 (see Figs. 3 and 4).

Air is supplied to'the cylinder under control of a valve 122 which in turn is operated by air under con trol of solenoid valves 124 and 126. Air is supplied through a pressure regulator to the high-pressure space a of the control valve 122 and exerts equal pressure on the two inner faces of small pistons 132 and 134. Air also passes through two bleeder parts 136 and 138 to the outer faces of the two large pistons 140 and 142, so that when the valves 124 and 126 are closed equal forces are applied to the outer faces of these pistons. The spaces between the two pistons 132 and 141. and between pistons 134 and 142 are opened to exhaust so that the pressures there are equal. Consequently as long as the solenoid valves 124 and 126 remain closed all forces acting on the four pistons are balanced and the valve remains in any position, as for example that shown. If now the solenoid valve 126 should be opened,

pressure will be exhausted from the right face of piston 142 faster than it can be supplied through the bleeder port 138. The resulting unbalance of forces will drive the pistons to the right. Subsequent closing of valve 126 will permit the pressures to equalize without causing further movement of the pistons.

When the valve 122 is in the position shown,- it supplies air under pressure through pressure-regulating valve 144 to the left end of cylinder 120 for urging the carriage 116 and the form-holder 34 toward the right. This pressure is maintained during the winding operation so that pin 121rides the steps of the cam 98 and thereby controls the motion of form-holder 34. During this op eration air is exhausted from the right end of cylinder 120 freely through a check valve 146 and the valve 122 to atmosphere. At the end of this operation solenoid valve 126 is opened briefly to shift the pistons of the valve 122 to the right for thereby applying air pressure to the right-hand end of cylinder 120 for retracting formholder 34 to the left. This air pressure is applied to cylinder 120 through throttle valve 148 for controlling the speed of the return motion. This return motion is limited by stop 152 on cam 98 against which pin 121 7 stops. Then solenoid valve 124 is opened to shift the pistons of valve 122 to the left for re-applying pressure to the left end of cylinder 120. This application of pressure moves the carriage 116 a fraction of an inch to the right to bring pin 121 against the first step of the cam. This is the stopping position of the machine as shown in Fig. 3.

Fig. 19 is a so-called across-the line diagram showing the electric control circuits. In this type of diagram each circuit extends in a substantially straight horizontal path across the power lines. Since this diagram doesnt always permit elements of a single piece of apparatus (such as the coils and contacts of a relay) -to be placed next to each'other, those elements of one relay or the like are indicated by the same letter. A pressure switch 154 (as shown in Fig. 18) permits the circuits to be energized only when the air pressure is on. A normally open push-button starting switch 156 suppliescurrent to a coil 158 of the main contactor M. Three pairs of normally open contacts 160 are closed by energization of this coil 158 for supplying three-phase power to the motor and brake 90. A switch 162 operated by the drum cam 98 (see also Fig. 25) closes shortly after the drum begins turning for maintaining the coil 158 of the main contact or M energized. A time-delay relay D has contacts 164 shunting the switch 162 to insure that the circuit will be kept closed even through the push-button 156 is released before the switch 162 has time to close. This relay D has a coil 166 energized through contacts 168 of the main contactor M. Relay D closes its contacts 164 immediately and then holds them closed for approximately two seconds. By that time switch 162 has been closed. Near the end of the winding operation, as the pin 121 drops over the 18th step of the drum cam 98, a bar 170 (see Fig. 18) which is moved by carriage 116, operates a limit switch 172. This switch energizes the coil 174 of a relay E which imposes a delay of two seconds and then closes its contacts 176 for energizing the solenoid valve 126 (also shown in'Fig. 18). At about this same time drum cam 98 opens switch 162 to deenergize coil 58 of relay M for stopping the motor and applying the brake. The opening position of this switch 162 is so set that the brake brings the machine to a stop with the form-supporting paddle 34 in the position shown in Fig. 3.

The energizing of solenoid 126 (just mentioned) causes the air pressure to return the carriage 116 to the left, as previously described, in which position bar 170 operates another limit switch 178 which energizes solenoid 124 for reapplying pressure to the left end of cylinder 120 and moving pin 121 against the first step of the cam, also as previously described. The machine has thus been brought back to its starting position and stopped. The wound heating element shown in Fig. 3 is removed from the machine and replaced by an empty form, as shown in Fig. 1.

Thus the moving parts of the machine of the present invention are compact, simple and light. The machine operates quieter, faster and more smoothly, and can be loaded and unloaded with less effort than the prior machine.

It will be apparent to those skilled in the art that my invention is capable of modifications and variations Within the scope of the appended claims.

I claim:

1. In a fiat-coil winding machine, in combination, a form holder for supporting a flat form for a coil, a Wirefeeding holder, means supporting one of said holders for rotational oscillation relative to the other about an axis of a form supported on said form holder, and means operable for shifting said form holder progressively stepby-step in the direction of said axis, and actuating means for rotatably oscillating said one holder and for shifting said form holder step-by-step progressively in one direction along said axis in timed relation to the oscillation.

2. In a flat-coil winding machine, in combination, a form holder for supporting a flat form for a coil, a wirefeeding holder, means supporting the form holder for rotational oscillation about an axis of a form supported thereon and for shifting movement along said axis, and

operating means for both rotatably oscillating said form holder about said axis and also shifting said form holder step-by-step progressively in one direction along said axis in timed relation to the oscillation thereof.

3. in a fiat-coil winding machine, in combination, a form holder for supporting a flat form for a coil, a wirefeeding holder, wire guides adjacent the positions of a pair of opposite edges of a form supported on said holder, actuating means for rotatably oscillating the form holder and wire guides together about an axis at least roughly parallel said edges, and means for shifting said form holder step-by-step progressively in one direction along said axis in timed relation to its oscillation, whereby said form holder moves along said axis relative to both the wire holder and the oscillating wire guides.

4. In a winding machine for laying a strand back and forth across a form in a plurality of spans between two spaced groups of span holders on said form, in combination, a form holder, a wire-feeding holder, means supporting one of said form and wire-feeding holders for non-linear oscillation relative to the other and actuating means for oscillating it through a path of such extent and orientation as to provide an angular displacement of said wire holder relative to said form holder exceeding 180 around an axis through said spans and transverse thereof, means operable for shifting said form holder in the direction of said axis, and actuating means for shifting said form holder step-by-step progressively in one direction along said axis in timed relation to the oscillation.

5. The combination of claim 4 wherein the wire-feed holder is stationary and the oscillation is executed by said form holder.

References Cited in the file of this patent UNITED STATES PATENTS 15,623 Stanton Aug. 26, 1856 440,811 Keats Nov. 18, 1890 456,671 Keats July 28, 1891 1,185,125 Nelson May 30, 1916 1,414,679 Turney May 2, 1922 1,990,237 Lloyd Feb. 5, 1935 1,998,714 Focha Apr. 23, 1935 2,329,434 Cave Sept. 14, 1943 2,453,749 Hilsinger, Jr Nov. 16, 1948 2,521,795 Kelley Sept. 12, 1950 2,589,503 McCullough Mar. 18, 1952 2,632,603 Hunsdorf Mar. 24, 1953 FOREIGN PATENTS 72,536 Austria Oct. 10, 1916 

